Method and apparatus for radial ultrasonic welding interconnected coaxial connector

Abstract

A coaxial connector assembly for interconnection with a coaxial cable with a solid outer conductor is provided with a monolithic connector body with a bore. A mating surface with a decreasing diameter toward a connector end is provided on an outer diameter of the connector body proximate the connector end. An overbody may be provided overmolded upon a cable end of the connector body. An interface end may be seated upon the mating surface, the interface end provided with a desired connection interface. The interface end may be permanently coupled to the mating surface by a molecular bond interconnection. In a method of interconnection, the interface end is coupled to the mating surface by application of radial ultrasonic welding.

I claim: 
     
       1. A coaxial cable-connector assembly, comprising:
 (a) a coaxial cable comprising: 
 an inner conductor; 
 an outer conductor circumferentially surrounding the inner conductor; and 
 a dielectric layer interposed between the inner conductor and the outer conductor; and 
 (b) a coaxial connector, comprising: 
 an inner contact electrically connected with the inner conductor of the coaxial cable; 
 an intermediate body positioned radially outwardly of the inner contact, the intermediate body electrically connected to the outer conductor of the coaxial cable via a circumferential molecular bond; and 
 an outer connector interface, electrically connected to the intermediate body, the outer connector interface configured to mate with an outer connector interface of a mating connector. 
 
     
     
       2. The assembly defined in  claim 1 , wherein the intermediate body has an internal bore, and wherein the molecular bond between the outer conductor of the coaxial cable and the intermediate body occurs in the internal bore. 
     
     
       3. The assembly defined in  claim 1 , wherein the outer connector interface circumferentially overlies at least a portion of the intermediate body. 
     
     
       4. The assembly defined in  claim 1 , wherein the outer connector interface is connected with the intermediate hotly via an interference fit. 
     
     
       5. The assembly defined in  claim 1 , further comprising an overbody that circumferentially overlies the intermediate body. 
     
     
       6. The assembly defined in  claim 1 , wherein the outer connector interface is configured to define a right angle connector. 
     
     
       7. The assembly defined in  claim 1 , wherein the outer conductor of the coaxial cable has a smooth profile. 
     
     
       8. A coaxial cable-connector assembly, comprising:
 (a) a coaxial cable comprising: 
 an inner conductor; 
 an outer conductor circumferentially surrounding the inner conductor; and 
 a dielectric layer interposed between the inner conductor and the outer conductor; and 
 (b) a coaxial connector, comprising: 
 an inner contact electrically connected with the inner conductor of the coaxial cable; 
 an intermediate body positioned radially outwardly of the inner contact, the intermediate body electrically connected to the outer conductor of the coaxial cable via a laser weld; and 
 an outer connector interface electrically connected to the intermediate body, the outer connector interface configured to mate with an outer connector interface of a mating connector. 
 
     
     
       9. The assembly defined in  claim 8 , wherein the intermediate body has an internal bore, and wherein the laser weld between the outer conductor of the coaxial cable and the intermediate body occurs in the internal bore. 
     
     
       10. The assembly defined in  claim 8 , wherein the outer connector interface circumferentially overlies at least a portion of the intermediate body. 
     
     
       11. The assembly defined in  claim 8 , wherein the outer connector interface is connected with the intermediate body via an interference fit. 
     
     
       12. The assembly defined in  claim 8 , further comprising an overbody that circumferentially overlies the intermediate body. 
     
     
       13. The assembly defined in  claim 8 , wherein the outer connector interface is configured to define a right angle connector. 
     
     
       14. The assembly defined in  claim 8 , wherein the outer conductor of the coaxial cable has a smooth profile. 
     
     
       15. A coaxial cable-connector assembly, comprising:
 (a) a coaxial cable comprising: 
 an inner conductor; 
 an outer conductor circumferentially surrounding the inner conductor; and 
 a dielectric layer interposed between the inner conductor and the outer conductor; and 
 (b) a coaxial connector, comprising: 
 an inner contact electrically connected with the inner conductor of the coaxial cable; 
 an intermediate body positioned radially outwardly of the inner contact, the intermediate body electrically connected to the outer conductor of the coaxial cable via a circumferential molecular bond; and 
 an outer connector interface electrically connected to the intermediate body, the outer connector interface configured to mate with an outer connector interface of a mating connector;
 wherein the intermediate body has an internal bore, and wherein the molecular bond between the outer conductor of the coaxial cable and the intermediate body occurs in the internal bore; and 
 wherein the outer connector interface circumferentially overlies at least a portion of the intermediate body. 
 
 
     
     
       16. The assembly defined in  claim 15 , wherein the outer connector interface is connected with the intermediate body via an interference fit. 
     
     
       17. The assembly defined in  claim 15 , further comprising an overbody that circumferentially overlies the intermediate body. 
     
     
       18. The assembly defined in  claim 15 , wherein the outer connector interface is configured to define a right angle connector. 
     
     
       19. The assembly defined in  claim 15 , wherein the outer conductor of the coaxial cable has a smooth profile. 
     
     
       20. A coaxial cable-connector assembly, comprising:
 (a) a coaxial cable comprising: 
 an inner conductor; 
 an outer conductor circumferentially surrounding the inner conductor; and 
 a dielectric, layer interposed between the inner conductor and the outer conductor; and 
 (b) a coaxial connector, comprising: 
 an inner contact electrically connected with the inner conductor of the coaxial cable; 
 an intermediate body positioned radially outwardly of the inner contact, the intermediate body electrically connected to the outer conductor of the coaxial cable via a circumferential laser weld; and 
 an outer connector interface electrically connected to the intermediate body, the outer connector interface configured to mate with an outer connector interface of a mating connector. 
 
     
     
       21. The assembly defined in  claim 20 , wherein the intermediate body has an internal bore, and wherein the laser weld between the outer conductor of the coaxial cable and the intermediate body occurs in the internal bore.